Technical Field
[0001] This invention relates to facing materials such as ceramic tiles which are installed
over substrates such as floors, ceilings and walls using a support plate or decoupling
mat between the substrate and the facing material to minimize or eliminate stresses
which may cause cracking or detachment of the facing material from the substrate.
Background Art
[0002] The use of facing materials, such as, ceramic tiles are well known to provide an
aesthetically pleasing appearance as well as durability and wear resistance. The following
description will be directed to ceramic tiles for convenience although it should be
appreciated by those skilled in the art that other facing materials such as stone
flooring, granite, slate, plastics, and the like, may be employed with the support
plate of the invention.
[0003] In general, ceramic tile is installed over a substrate such as a wooden floor using
a mortar to set the tile. Unfortunately, because of the differences in properties
between the substrate, mortar, and ceramic tile, stresses formed during such installation
often result in damage in the form of cracks or delamination. Previously, most ceramic
tile installations utilized mud setting beds, wherein a mixture of sand and cement
was applied over the floor or other substrate and the ceramic tile set in the mud.
The mud beds were generally in the range of about 1½ inch thick.
[0004] Modern ceramic tile installations now often use thin layer processes, which require
use of thin-set mortar systems wherein the thickness of the thin-set mortar is about
½ inch thick. Flooring systems of this type are generally less costly, lighter, and
more easily coordinated with installations of ceramic tile and stone.
[0005] Because of the thinness of the installation however, stresses at the interface between
the mortar, substrate, and ceramic tile are much greater than in the case of a thin
bed installation and it has been found that these stresses cause cracking of the tile
and/or delamination of the tile of the floor. In an effort to decrease the stress
differences and the problems of tile cracking and delamination, support plates or
otherwise known as decoupling or uncoupling plates/mats have been developed. Currently
available support plates are used between the substrate and the ceramic or stone tile
to provide a base for the tile, as well as to decrease or eliminate the stresses in
the installation. A number of support plates have been developed as indicated in the
following patents.
[0006] U.S. Patent No. 4,917,933 discloses a plastic sheet that is used as a sub-carrier and provides a series of
parallel, alternating, dovetailed-shaped channels and grooves. A cross-meshed lattice
matting, having filaments, is glued or partially fused to the backside of the plastic
sheet and serves to anchor the sheet to the underlying foundation.
[0007] In
U.S. Patent No. 5,255,482 a support plate is used between a rigid horizontal base and a top flooring layer
(i.e., tile). The support plate is a crack isolation layer that comprises a hard,
essentially rigid material, that is in load bearing relationship with the base and
the top flooring layer. The crack isolation layer comprises precast rigid crack isolation
sheets having recesses or holes. Alternatively, the crack isolation layer comprises
a plurality of spaced pilings of rigid, non-compressible material, which are mounted
in spaced apart relationship on a cloth matting.
[0008] U.S. Patent No. 6,434,901 shows another support plate of a sheet material having a number of recesses therein.
Each recess within this support plate has overhangs that define undercut portions
therein that entrap mortar in the recess and provide a secure bond between a ceramic
tile and the support plate. The support plate is positioned on the substrate and secured
thereto, and then thin-set mortar is applied to the surface of the support plate and
fills the recesses within such plate.
[0009] In UK Patent Application
GB 2141459 a drainage plate is shown having stamped-out portions recessed on one side of the
plate with u-shaped openings provided in the inclined laterals walls of the these
recessed portions to permit water to pass there-through. The drainage plate is installed
between the substrate and the ceramic tile.
[0010] In
U.S. Patent No. 7,536,83 a support plate having support elements that are hollow towards the underside, capable
of support, and project out beyond the top of the support plate, is applied on the
sub-floor. Channels carrying open water are formed between the support elements and
a water-permeable covering that is disposed on the support elements. The support plate
is embedded in a thin-bed mortar layer on the sub floor, and ceramic tiles are laid
and attached to a covering (non-woven fabric) residing on the other side of the support
plate.
[0011] In U.S. Publication Application No.
US/2006/0201092, another support plate is shown for achieving a coupling between the base and a surface
cladding. This support plate has multiple open chambers with a net-like fabric attached
at the open end of such chamber. A thin-set mortar is applied over the support plate
to fill the chambers and secure the mortar to the plate via the net-like fabric for
attaching the support plate to the ceramic tile.
[0012] Unfortunately, while the prior art has developed a number of support plates to be
used in ceramic and stone tile installations, each of these prior art support plates
continues to introduce some level or degree of unwanted stress cracking and/or delamination.
As such, there is still a need for improved support plates that decrease and/or avoid
stress cracking of the tiles, while also decreasing and/or avoiding delamination of
the tiles caused by stresses resulting in the installation.
Disclosure of Invention
[0013] Bearing in mind the problems and deficiencies of the prior art, it is therefore an
object of the present invention to provide a support plate for installing facing materials
such as ceramic and stone tiles on substrates such as floors, ceilings and walls wherein
the support plate minimizes and/or eliminates stresses which may cause cracking or
detachment of the set tile.
[0014] It is another object of the present invention to provide a flooring installation
wherein facing materials such as ceramic and stone tiles are installed over a substrate
such as floors and ceilings wherein a support or decoupling plate is used between
the substrate and the ceramic or stone tile to minimize and/or eliminate stresses
which may cause cracking or detachment of the set tile to the substrate.
[0015] In one or more embodiments, the invention is directed to a support plate for installing
facing materials on a substrate. The support plate includes a sheet material having
a top surface and a bottom surface, and a plurality of spaced apart adjacent recesses
residing across the sheet material with each recess open at the top and having a bottom
and sidewalls comprising the sheet material. Together the sheet material and the recesses
define a plate having a thickness extending from a top surface of the plate to a bottom
surface of the plate. The support plate also includes an underlay mat attached to
the bottom surface of the plate. A plurality of slots traverse through the sheet material
at the top surface of the plate and reside between the adjacent recesses.
[0016] In other embodiments, the invention is directed to support plate for installing tile
on a substrate. The support plate includes a sheet material having a top surface and
a bottom surface, and a plurality of circular recesses spaced apart from a plurality
of adjacent flared-square recesses. These circular and flared-square recesses reside
across the sheet material and have bottom and sidewalls comprising the sheet material.
Together the sheet material and the circular and flared-square recesses define a plate
having a thickness extending from a top surface to a bottom surface thereof. The support
plate also includes an underlay mat attached to the bottom surface of the plate. A
plurality of open slots traverse through the sheet material at the top surface of
the plate and expose a top surface of the underlay mat. These plurality of open slots
reside between and connect at least one circular recess to an adjacent at least one
flared-square recess.
[0017] In still other embodiments, the invention is directed to a method of installing facing
materials. The method includes providing a substrate, and depositing a first mortar
over the substrate followed by attaching a support plate to the substrate via the
first mortar. The support plate includes a sheet material having a top surface and
a bottom surface, and a plurality of adjacent recesses residing across the sheet material.
Together the sheet material and the recesses define a plate having a thickness extending
from a top surface of the plate to a bottom surface of the plate. The support plate
also includes an underlay mat attached to the bottom surface of the plate. A plurality
of slots traverse through the sheet material at the top surface of the plate and reside
between the adjacent recesses. A second mortar is then deposited over the support
plate to fill both the plurality of recesses and the plurality of slots. This second
mortar residing within the plurality of slots contacts the second mortar residing
within the plurality of recesses. A facing material is then provided over the second
mortar.
Brief Description of the Drawings
[0018] The features of the invention believed to be novel and the elements characteristic
of the invention are set forth with particularity in the appended claims. The figures
are for illustration purposes only and are not drawn to scale. The invention itself,
however, both as to organization and method of operation, may best be understood by
reference to the detailed description which follows taken in conjunction with the
accompanying drawings in which:
Fig. 1A is a cross-sectional view of a prior art support plate secured to a substrate.
Fig. 1B is a top plan view of the support plate of Fig. 1A taken along line 1-1' of
Fig. 1A.
Fig. 2A is a top plan view of a support plate in accordance with one or more embodiments
of the invention.
Figs. 2B-2E are cross-sectional perspective views of the support plate of Fig. 2A
taken along the various lines therein.
Figs. 3A-3E are top plan and cross-sectional perspective views showing an installation
system of various embodiments of the invention using the support plate shown in Figs.
2A-2E.
Fig. 4A is a top plan view of another support plate of other embodiments of the invention.
Figs. 4B-4D are cross-sectional perspective views of the support plate of Fig. 4A
taken along the various lines therein.
Figs. 5A-5D are top plan and cross-sectional perspective views showing an installation
system of one or more embodiments of the invention using the support plate shown in
Figs. 4A-4D.
Figs. 6A-6D are top plan views showing various configurations and paths that interconnecting
slots of the invention may reside across the different support plates of the invention.
Figs. 7A-7B are top plan and cross-sectional perspective views of other slots of the
invention residing across the present support plates.
Figs. 8A-9B show support plates in accordance with one or more embodiments of the
invention having different shaped recesses connected or adjoined together by open
slots residing across the planar upper surface of the present support plates.
Description of the Preferred Embodiments)
[0019] In describing the preferred embodiment of the present invention, reference will be
made herein to Figs. 1-9B of the drawings in which like numerals refer to like features
of the invention.
[0020] Referring to the drawings, Figs. 1A and 1B show a conventional prior art support
plate 105, such as, those described above. The support plate 105 is installed over
a substrate 100, such as a floor, using mortar 102. The support plate 105 is a sheet
of plastic material having a number of recesses 120 formed across and within the support
plate. Each recess 120 has sidewalls and a bottom wall composed of the support plate
material. Raised portions of the support plate material reside between the recesses
120 with empty cavity regions 106 residing under the raised portions of the support
plate.
[0021] Attached to the bottom of the support plate 105 is a fabric-like mat 104. In attaching
the support plate 105 to the substrate 100, the mortar 102 residing over the substrate
100 impregnates the fabric-like mat 104 to secure the support plate to the substrate.
A thin-set mortar 200 is then applied over the support plate 105 to provide a base
for the installation of tiles and grout over the support plate (not shown).
[0022] As shown from the side view of Fig. 1A, and the top plan view of Fig. 1B (along line
1-1' of Fig. 1A), the thin-set mortar 200 fills only the recesses 120 and contacts
the sidewalls and bottoms of such recesses. Since the support plate material resides
over the empty cavity regions 106, which reside under or at a backside of the support
plate, the thin-set mortar 200 does not penetrate, contact or fill such empty cavity
regions 106. As such, the fabric-like mat 104 that is exposed within these empty cavity
regions 106 (see, Fig. 1B) does not contact the thin-set mortar 200.
[0023] These empty cavity regions 106 of the plate are not as strong under pressure as compared
to those sections of the plate filled with thin-set mortar 200 (e.g., the recesses
120 filled with mortar 200). As such, the empty cavity regions 106 impart weak and
less durable portions of the conventional support plate 105 that allow for movement
in and of the laid support plate, which in turn, may induce stress cracking and/or
delamination of the tiles and/or grout residing on top of the thin-set mortar 200.
[0024] Unlike that of the conventional prior art support plates 105 shown in Figs. 1A-B,
the support plates of the present invention improve the durability of the laid support
plate to decrease and/or avoid stress cracking and/or delamination in facing materials
(e.g., tiles on substrates such as floors, ceilings, walls, etc.) and in the mortars
used to lay such facing materials. Figs. 2A-9B show one or more embodiments of support
plates of the invention. Again, while the present invention is described generally
in connection with ceramic tiles for ease of understanding the invention, it should
be appreciated by those skilled in the art that other facing materials, such as, stone
flooring (tile), granite, slate, plastics, and the like, may be employed with the
various support plates of the invention. It should also be appreciated that while
reference is made herein to a support plate, the various support plates of the invention
are may also be referred to as a decoupling plate/ mat/ or membrane, uncoupling plate/
mat/ or membrane, support mat/ or membrane, underlayment, and the like.
[0025] Referring to Figs. 2A-2E, a support plate in accordance with one or more embodiments
of the invention is shown generally as numeral 10A. The support plate is made of a
material 5, such as a foil-like plastic material, and has a top surface 11 and a bottom
surface 12. The support plate may be composed of a high-density polyethylene or polypropylene
plastic material. Fig. 2A shows a top plan view of the support plate 10A having a
number of recesses 20 formed across the support plate 10A. Since the recesses 20 are
formed in the sheet material 5 of the plate 10, such recesses have a similar sidewall
thickness and base thickness as that of the material 5.
[0026] The support plates of the invention are in communication with and/or attached to
an underlying fabric-like mat 4. The underlying mat 4 may be bonded, adhered to, or
attached to the support plate material 5 to from the various support plates of the
invention. The underlying mat 4 may include a non woven fabric material, a woven fabric
material, and the like. In one or more embodiments the underlying mat 4 may be composed
of a polypropylene spun bond fabric.
[0027] Residing across the support plate 10A is a number of slots 30A that provide increased
durability to the present laid support plate. Referring to one or more embodiments
of the invention, adjacent recesses 20 may be connected to each other along one or
more planes by slots 30A. For instance, Fig. 2A shows adjacent recesses 20 adjoined
together by slots 30A along an x-plane. However, it should be appreciated that the
adjacent recesses may be adjoined along the y-plane, adjoined along both the x-plane
and y-plane, or even at scattered locations across the x-, y-planes.
[0028] While the slots 30A are shown in Fig. 2A as recessed slots that adjoin adjacent recesses
20 along a single path (e.g., row, column, etc.), it should be appreciated and understood
that in certain embodiments of the invention, as discussed in detail below, the slots
are open slots 30B that connect adjacent recesses 20 while simultaneously exposing
underlying fabric-like mat 4. Still further discussed below, in other embodiments
the slots may be openings 30 that do not connect adjacent recesses 20, but rather
provide an opening within the material 5 of the support place 10A to expose the underlying
fabric-like mat 4.
[0029] Referring again, to Fig. 2A, while the slots 30A are shown as recessed slots that
adjoin adjacent recesses 20 along a single path (e.g., row, column, etc.), it should
be appreciated and understood that such slots 30A may have any shape, and reside along
any path, that allow for two or more recesses to be joined together. For instance,
while not meant to limit the invention, the slots 30A may be L-shaped, X-shaped, H-shaped,
C-shaped, T-shaped, square-shaped, rectangular, circular, triangular, or any other
geometric or polynomial shape that allows for two, three, four or more recesses to
be connected together, regardless of whether each and all the connected recesses are
adjacent to one another. It should further be appreciated that in certain embodiments,
as discussed further below in relation to Figs. 7A-7B, the slots 30A in the present
support plates need not adjoin adjacent recesses.
[0030] Referring to Figs. 2B-E, cross-sectional perspective views of a support plate of
the invention is shown along lines 1A-1A', 2A-2A', 3A-3A' and 4A-4A' of Fig. 2A, respectively.
In one or more embodiments, the material 5 of the support plate resides at the top
surface 11 of the support plate 10A, along sidewalls 22A of recesses 20, at the bottom
of recesses 20, and may even reside along sidewalls 32A of slots 30A, and at the bottom
of slots 30A.
[0031] In other embodiments of the invention, as discussed in detail below in reference
to Figs. 4A-9B, the material 5 of the support plate does not reside along the sidewalls
32A of openings nor at the bottom thereof. Rather, in these embodiments the slots
30A are open slots that traverse through the material 5 of the support plate 10B to
form apertures therein and expose the underlying fabric-like mat 4 of the plate.
[0032] Figs. 2A-3E show embodiments of the invention wherein the present support plates
10A may have material 5 of the plate extending across the entire support plate (i.e.,
having no open voids that expose the underlying fabric-like mat 4 as in Figs. 4A-9B).
In the embodiments shown in Figs. 2A-3E the slots 30A are recessed (i.e., recessed
slots) and both adjoin and physically connect two or more recesses 20 to each other,
whether such recesses are adjacent to one another or not.
[0033] Fig. 2B shows that along line 1A-1A', which is substantially at the center of the
recesses 20 and adjoining slots 30A, the support plate material 5 extends across all
bottoms of the recesses 20 and slots 30A. Fig. 2C shows portions of the sidewalls
32a of slots 30A, portions of sidewalls 22a of recesses 20, as well as the support
plate material 5 residing at the bottoms of such recesses 20 and slots 30A along line
1B-1B' of Fig. 2A.
[0034] Referring to Fig. 2D, it is shown that the plate material 5 resides across the entire
support plate 10A with regions where the recesses 20, their sidewalls 22A and recess
bottoms, as well as regions where the slots 30A, their sidewalls 32A and their bottoms,
all have the support plate material 5. In particular, Fig. 2D shows a perspective
view along line 3A-3A' in the x-direction whereby the material 5 of the plate resides
at the top surface 11 of the plate and within all portions of the recesses 20. The
empty cavity regions 6 are shown residing between adjacent recesses 20.
[0035] Fig. 2E shows a perspective view along line 4A-4A' in the y-direction whereby the
material of the plate resides across its top surface 11, within the recesses as shown
by the portions of recess sidewalls 22A, and within slots 30A along the openings sidewalls
32A and bottom surface. As shown, the slots 30A have a narrower width as compared
to a width of the recesses 20 formed in the plate 5. Again, as will be understood
in accordance with the description of the present invention, these recessed slots
of these embodiments of the invention may connect two, three, four or more recesses
20 within the plate 5.
[0036] Figs. 3A-3E show a method of installing the support plate of Figs. 2A-E over an adhesive
or mortar 102 (e.g., a cementious mortar) to secure the plate to a substrate 100 including,
for instance, a floor, ceiling, wall, angled surface, etc. In doing so, the adhesive
or mortar 102 is deposited over the substrate 100 followed by providing the support
plate 10A of the invention over the mortar 102 and pressing the plate into place within
the mortar 102. The fabric-like mat 4 at the underside 12 of the plate maximizes bonding
of the support plate 10A to the substrate 100 via the mortar 102. A thin-set mortar
200 is then applied over the support plate 10A to provide a base for the installation
of facing materials 300 and grout 310 thereover.
[0037] Figs. 3A-B show that the mortar 200 completely fills both recesses 20 and slots 30A,
and contacts the material 5 of the support plate at the bottom of such recesses and
openings. Figs. 3C-E show alternate views of the mortar filled support plate of these
embodiments of the invention. As is shown, the mortar 200 entirely fills the recesses
20 and slots 30A, making contact with recess sidewalls 22A, recess bottoms, opening
sidewalls 30A and opening bottoms, and completely covers the top surface 11 of the
plate.
[0038] In those embodiments of the invention having recessed slots 30A, such recessed slots
provide additional exposed support plate surface areas that the mortar 200 contacts,
and they decrease the area of empty cavity regions 6 residing between the support
plate 10A and substrate 100 while maintaining sufficient separation between such substrate
and facing materials. As a result, the recessed slots 30A of the invention provide
increased durability and strength to the present support plates 10A. This increased
durability and strength leads to reduced stress cracking and delamination of facing
materials and/or grout residing over such plates. The mortar within the recessed slots
30A also provides increased or enhanced mechanical bond of facing materials to the
mortar 200 to the plate 10A.
[0039] Referring to other embodiments of the invention, Figs. 4A-5D show one or more embodiments
of support plates of the invention as described in detail below. In these embodiments
of the invention, each support plate 10B is composed of a material 5 (e.g., a foil-like
plastic material), and has top surface 11 and bottom surface 12. The top plan view
of Fig. 4A shows the support plate 10B having a number of recesses 20, each with the
support plate material 5 residing along the recess sidewalls 22B and bottoms thereof.
The support plate 10B also has a number of open slots 30B that traverse through the
support plate material 5 and expose the underlying fabric-like mat 4 that is in communication
with and/or bonded, adhered or attached to the support plate material 5 to form support
plate 10B.
[0040] The open slots 30B provide increased durability to the present laid support plate
10B and decrease both cracking and delamination problems. These open slots 30B may
be provided within the present support plates 10B by a variety of known techniques
including, but not limited to, cutting openings within the plate, stamping or punching
openings within the plate, molding a plate having such openings, and the like. These
support plates 10B have a number of open slots 30B that do not have bottoms and thereby
expose the underlying mat 4 of the plate. The open slots 30B exposing the underlying
mat 4 material may either contact and connect adjacent recesses 20 to each other (see,
e.g., Figs. 4A-5D), or they may reside between adjacent recesses 20 and not contact
any of such recesses (see, e.g., Figs. 7A-7B).
[0041] In one or more embodiments, the open slots 30B may have no bottoms or sidewalls.
Rather, they are provided as cuts or openings within the support plate material 5
to expose the underlying mat material 4. In other embodiments, the support plates
may be fabricated with the open slots 30B whereby such slots 30B are open at the bottom
(i.e., have no bottoms) but have sidewalls that define a pillar column that is to
be formed upon application of a thin-set mortar. In these embodiments, the sidewalls
may be provided to form a conical, tubular or other trapezoidal shape, all of which
have no bottom material (mat 4 is exposed) that is capable of being filled with mortar.
These sidewalls may be either straight sidewalls, or they may be transverse or angled
sidewalls to form transverse or angled open slots 30B. In each of these embodiments
of the invention the slots 30B at least expose the underlying mat 4 to provide a strong
interlocking bonding connection between the mat 4, mortar 200 provided over the support
plate, the support plate itself, and facing material (e.g., tile) provided over the
mortar 200 and support plate.
[0042] Again, it should be appreciated that the openings within the support plates of the
invention may be open slots 30B of any shape or size, and reside along any path, that
allow for two or more recesses to be joined together. For instance, the open slots
30B may be L-shaped, X-shaped, H-shaped, C-shaped, T-shaped, square, rectangular,
circular, triangular, or any other geometric or polynomial shape, or even combinations
thereof (see, e.g., Figs. 6A-6D), that allows for two, three, four or more recesses
to be connected together, regardless of whether each and all the connected recesses
are adjacent to one another. In one or more support plates of the invention, a combination
of slots (i.e., recessed slots or open slots) may be provided that connect one or
more recesses together in combination with openings residing between and not contacting
any recesses.
[0043] Referring to Figs. 4B-D, support plate 10B is shown respectively along lines 1B-1B',
2B -2B', 3B - 3B' and 4B-4B' of Fig. 4A. As is shown, the open slots 30B form apertures
or voids in the support plate material 5 and expose the underlying mat 4 at those
portions of the plate 10B where such open slots 30B reside. Fig. 4B shows a perspective
view of the plate 10B along line 1B-1B' in the x-direction. The open slots 30B traverse
through the plate material 5, such that, the plate material 5 resides only at the
bottoms of the recesses along line 1B-1B' as is shown by reference numerals 20. Alternatively,
as shown by reference numeral 20" in Fig. 4B, the open slots 30B may traverse through
the raised portion of the support plate 10B and partially into the sidewall 22B of
the recess 20". In this manner a portion of the recess 20" sidewall may remain within
the support plate 10B.
[0044] Fig. 4C shows a perspective view in the x-direction along lines 2B -2B' and 3B -3B'.
As shown, the open slots 30B are provided or formed in the support plate 10B such
that they have sidewalls 32B having a length that is substantially equivalent to the
thickness of the support plate material 5 itself. A perspective view in the y-direction
along line 4B -4B' is also shown in Fig. 4C (however, the sidewall portion 22B of
recesses 20 is not shown). Again, the plate material 5 resides across the raised portion
of the plate 10B and within the recesses 20. Referring to Fig. 4D, a perspective view
in the y-direction along line 5B -5B' is shown. This line 5B -5B' resides across the
plate 10B and across the open slots 30B. The material 5 of the plate does not reside
in locations where open slots 30B reside, such that, an upper surface of the underlying
mat 4 material is exposed.
[0045] Figs. 5A-D show a method of installing the support plate 10B of Figs. 4A-D over adhesive
or mortar 102 to secure the plate to a substrate 100 including, for instance, a floor,
ceiling, wall, angled surface, etc. The support plate is secured to the substrate
100 by adhesive or mortar 102 impregnating and adhering to the mat 4 of the plate
10B as described above. A thin-set mortar 200 is then applied over the support plate
10B to provide a base for the installation of facing materials 300 and grout 310.
The mortar 200 is pressed into and completely fills the recesses 20 and open slots
30B.
[0046] Referring to Fig. 5D, in those portions of the plate 10B where open slots 30B reside,
the mortar 200 fills such open slots 30B with a portion of mortar 210 extending out
and under the plate 10B at locations corresponding to such slots 30B. In so doing,
pillars of mortar 210 reside under the raised portion of the plate 10B and extend
between the bottom surface 12 of material 5 of the raised portion of the plate 10B
and an exposed upper surface of the underlying mat 4.
[0047] The deposited mortar 210 may form mortar pillars of an essentially trapezoidal prism
shape or cone shape within these open slots 30B. At select locations (see, e.g., selected
mortar 210 in Fig. 5D), or at all locations, the deposited mortar 210 may flow under
and spread out underneath the raised portion of the plate 10B with a portion thereof
penetrating under and contacting the underside 12 of the plate. The degree to which
the mortar 210 spreads out underneath the underside 12 of plate 10 depends on various
factors including, but not limited to, the amount of mortar 200 deposited, the amount
of pressure applied by an installer during installation of the mortar 200 over plate
10, the viscosity of the mortar 200 used (i.e., degree of mortar wetness), and the
like. This penetrating portion of mortar 210 is retained or resides under the support
plate 10B in these non-recess 20 regions of the plate to form an interlocking structure
of the mortar 200, 210 with the support plate 10B and the underlying mat 4 of the
plate 10B.
[0048] The mortar 210 between the bottom surface 12 of the raised plate portion and the
mat 4 makes direct contact with both the underside of support plate 10B and the upper
surface of the mat 4 to form an interlocking bond there-between. These retained portions
of mortar 210 residing under and contacting the underside 12 of the support plate
10B and the mat 4 provide increased or enhanced mechanical bonds between facing materials
to the mortar 200 and to both the plate 10B and its underlying mat 4. These pillars
of mortar 210 also reduce the amount of empty cavity regions 6 residing between the
underside support plate 10B and the mat. Mortar 210 provides the support plates of
the invention with increased durability and strength as discussed below, and also
aid in more rapid hydration of the cementious mortar.
[0049] The support plates 10B of Figs. 4A-5D provide additional surface area for the mortar
200 to contact, decrease the area of the empty cavity regions 6 residing between the
top of the plate and mat, as well as provide increased durability and strength to
the plate by reducing the amount of weak and/or less durable locations or portions
of the support plate. Again, this increased durability and strength of the present
support plates minimize and/or eliminate stress cracking and delamination of facing
materials and/or grout residing over such plates.
[0050] While the invention has been described above in conjunction with various embodiments
thereof, it should be appreciated and understood that numerous different support plates
may be envisioned within the scope of the present invention. For instance, referring
to Figs. 6A-6D the slots 30, which may be recessed slots, open slots or combinations
thereof, may be connected along a variety of paths or planes. These paths may include,
for instance, diagonal paths residing in a single plane-direction, or a plurality
of crossed lines whether they are diagonal, horizontal or vertical, and whether such
crossed lines reside across the entire support plate or just portions thereof.
[0051] It should also be appreciated and understood that the slots 30 within the present
support plates are not limited to lines residing along vertical or horizontal paths.
Again, referring to Figs. 7A-7B, such slots 30 may be a plurality of individual perforated
slots 30C that reside across the support plate in locations that are adjacent to or
between recesses 20 while not contacting such recesses 20. In one or more embodiments,
these perforated slots 30C are openings that transverse through the plate material
5 to expose the underlying mat 4.
[0052] While the perforated slots 30C in Figs. 7A-B are shown as circular open perforated
slots 30C, it should be appreciated that the perforated slots 30C may have a variety
of different shapes and sizes that allow for a sufficient amount of mortar 200, 210
to fill such perforated slots 30C and provide the laid support plate of the invention
having increased durability and strength. Shapes of perforated slots 30C not contacting
adjacent recesses 20 may include, but are not limited to, circular, square, rectangular,
oval, crossed line/slot segment openings, or any other geometrical or polynomial shape,
or even combinations thereof. In certain embodiments, the perforated slots 30C may
even be of different shapes, dimensions and/or widths on a support plate. However,
in each of the embodiments, these perforated slots 30C reside between recesses 20
and do not contact or interfere with these recesses 20.
[0053] In still other embodiments of the invention, it should be appreciated that the recesses
20, while shown as circular shapes in Figs. 2A-7B, are not limited to this shape and
may have any desired shape, for example, square, rectangular, oval, any other geometrical
or polynomial shape, or even combinations of any of the foregoing. In one or more
embodiments, the support plates 10 of the invention may include a combination of two
or more staggered shapes. For instance, Figs. 8A-9B show a combination of circular
recess shapes 20 in combination with flared-square recess shapes 21, whereby the circular
and flared-square shapes reside in an alternating pattern along both the x-plane and
y-plane. Both the circular recesses 20 and the flared-square recesses 21 have planar
bottom surfaces and sidewalls for receiving mortar 200.
[0054] In accordance with the invention, the various support plates 10 of the invention
may have a variety of different thickness', lengths and widths, which are ultimately
dependent upon the end use of such support plate. In one or more embodiments, the
entire support plate 10 may have a thickness ranging from about 1.5 to 13 mm (about
1/16 to 1/2 inches), preferably from about 1.5 to 3.2 mm (about 1/16 to 1/8 inches).
The support plate material 5 may have a thickness of about 0.55 mm, with a tolerance
ranging from about 0.3 to 0.7 mm. The underlying mat 4 may be composed of polypropylene
spun bond material having a mat weight of about 70 g/sq mt, with a tolerance ranging
from about 30-150 g/sq mt. In these embodiments, both recesses 20, 21, etc. and slots
30 (i.e., 30A, 30B, 30C, etc.) may have depths corresponding to the thickness of the
support plate 10 (i.e., have depths ranging from about 1.5 to 12.7 mm, preferably
from about 1.5 to 3.2 mm). Those slots 30A, 30B contacting and connecting adjacent
recesses 20, 21 have lengths corresponding to the distance between such recesses being
connected, and may have widths ranging from about 3 to 35mm, or even more or less.
The width of recesses 20, 21 may vary widely depending on the use, and in certain
embodiments may have a diameter ranging from about 10 to 65 mm, or even more or less.
[0055] Referring to one or more embodiments of the invention as shown in Figs. 8A-9B, a
support plate 10D is shown having circular recesses 20 in combination with flared-square
recess 21. Again, these different patterned recesses 20, 21 reside in an alternating
pattern across the support plate 10D in both the x-plane and y-plane. Since the flared-square
recess shapes take up increased surface area of the plate, as compared to circular
recesses alone, an increased amount of mortar 200, 210 is retained within and over
the support plate. The support plate 10D of Figs. 8A-9B may be composed of a high-density
polyethylene material 5 having a thickness of about 0.25 mm to about 1.25 mm, preferably
about 0.55mm. The underlying mat 4 may be a polypropylene spun bond material having
a mat weight of about 70 g/sq mt, with a tolerance ranging from about 30-150 g/sq
mt.
[0056] As shown in Figs. 8A-9B, the support plate 10D may have a depth or thickness ranging
from about 1.5 to 13 mm, preferably from about 1.5 to 3.2 mm, and most preferably
about 2.75 mm, with the recesses 20, 21 also have depths corresponding to (or the
same as) the support plate 10D. The diameter of the circular recesses 20 may range
from about 5 to 60 mm (or more or less), preferably from about 13 to 35 mm, and most
preferably about 20 mm. The diameter of the flared-square recess 21 residing along
the diagonal thereof (i.e. at its largest diameter) may range from about 5 to 70 mm
(or more or less), preferably from about 13 to 63 mm, and most preferably about 28
mm, with the smaller inner portion of such flared-square recesses having diameters
corresponding to its diagonal diameter.
[0057] The center from one circular recess 20 to the center of an adjacent flared-square
recess 21 may have a length ranging from about 6 to 75 mm (or more or less), preferably
from about 11 to 66 mm, and most preferably about 26 mm. The open slots 30A each have
a length corresponding to the distance between the outer edge of one recess 20 to
the outer edge of the adjacent recess 21 for which such open slot 30A makes a connection
between. That is, the open slots 30A each have a length corresponding to the distance
between adjacent recesses 20, 21 that the slot 30A connects together. The width of
the open slots 30A may range from greater than 0 mm up to about 50 mm (or more or
less), preferably from about 3.5 to 25 mm, and most preferably about 4.5 to 9 mm.
While the foregoing provides ranges for the width of the slots 30 (i.e., 30A, 30B,
30etc.) of the invention, it should be appreciated that such slots 30 may have a width
that corresponds to the size of the recesses 20, 21 that are being adjoined by such
slots 30.
Example 1:
[0058] Support plate in accordance with one or more embodiments of the invention as shown
in and described above in connection with Figs. 8A-9B (e.g., the most preferred embodiment
thereof) was installed over a 48" x 59 " plywood base. The plywood base was a 23/32"
Exposure 1 T&G plywood subfloor adhered to and nailed to four 2" x 2" joists spaced
19.2" O.C. (on center). A thin-set mortar 102 mixed with water was troweled over the
plywood subfloor with a 1/4" x 3/16" V-notched trowel using known application techniques.
A support plate 10D of the invention was laid into the thin-set and smoothed with
a grout float and rolled with a 35 pound roller to eliminate air pockets. The system
was then allowed to cure for 24 hours.
[0059] A thin-set mortar 200 mixed with water was deposited over the support plate 10D of
the invention using a 1/4" x 3/8" square-notched trowel. During the installation,
the mortar 200 was applied in a sufficient amount and with both sufficient pressure
and care to ensure that the mortar 200 filled recesses 20, 21 and filled the open
slots 30A to form mortar pillars 210 residing underneath the backside 12 of the plate
10D material 5. A plurality of 12" x 12" porcelain tiles were set in the thin-set
by pressing down and sliding the tiles in a direction perpendicular to combed ridges
of the mortar 200. After the tiles were installed, the thin-set mortar 200, 210 was
allowed to cure for 24 hours before grouting.
[0060] A water-based grout was forced into the 1/8" grout joints using a rubber float, and
excess grout was removed. The grout was allowed to set for approximately 20 minutes
before the installation was cleaned with a sponge and water. The grouted installation
was subsequently allowed to cure for 28 days.
[0061] At the end of this cure period, the installed system was subjected to load cycling
as defined in ASTM C627. The deflection of the plywood subfloor was measured in the
wheel path, midway between the 19.2" O.C. joists. The installed system completed all
fourteen cycles with no evidence of damage to the tile or grout joints. The maximum
deflection of the plywood subfloor during cycling was approximately 0.053". All evaluation
criteria were based on 8 tiles and 8 grout joints in the wheel path of the Robinson-Type
Floor Tester. In accordance with the Performance Level Requirement Guide and Selection
Table of the 2012
TCNA Handbook for Ceramic, Glass, and Stone Tile Installation (page 31), the tested installed system of the invention is classified as "EXTRA HEAVY".
Example 2:
[0062] Support plate like that implemented in Example 1 was installed over a 48" x 49.5"
plywood base. The plywood base was a 23/32" Exposure 1 T&G plywood subfloor adhered
to and nailed to four 2" x 2" joists spaced 16" O.C. Mortar 102, support plate 10D,
thin-set mortar 200, tiles and grout were all installed as described in connection
with Example 1 above.
[0063] At the end of the grout cure period, this installed system was subjected to load
cycling as defined in ASTM C627. The deflection of the plywood subfloor was measured
in the wheel path, midway between the 16" O.C. joists. The installed system completed
all fourteen cycles with no evidence of damage to the tile or grout joints. The maximum
deflection of the plywood subfloor during cycling was approximately 0.031 ". All evaluation
criteria were based on 8 tiles and 8 grout joints in the wheel path of the Robinson-Type
Floor Tester. In accordance with the Performance Level Requirement Guide and Selection
Table of the
2012 TCNA Handbook for Ceramic, Glass, and Stone Tile Installation (page 31), the tested installed system of the invention is classified as "EXTRA HEAVY".
[0064] While the present invention has been particularly described, in conjunction with
a specific preferred embodiment, it is evident that many alternatives, modifications
and variations will be apparent to those skilled in the art in light of the foregoing
description. It is therefore contemplated that the appended claims will embrace any
such alternatives, modifications and variations as falling within the true scope and
spirit of the present invention.
Clauses:
[0065]
- 1. A support plate for installing facing materials on a substrate comprising:
a sheet material having a top surface and a bottom surface;
a plurality of spaced apart adjacent recesses residing across the sheet material with
each recess open at the top and having a bottom and sidewalls comprising the sheet
material, together the sheet material and the recesses define a plate having a thickness
extending from a top surface to a bottom surface thereof;
an underlay mat attached to the bottom surface of the plate; and
a plurality of slots traversing through the sheet material at the top surface of the
plate and residing between the adjacent recesses.
- 2. The support plate of clause 1 wherein the sheet material comprises a plastic material.
- 3. The support plate of clause 1 wherein the spaced apart recesses have a single shape.
- 4. The support plate of clause 1 wherein the spaced apart recesses comprise a pattern
of two or more different shaped recesses.
- 5. The support plate of clause 1 wherein the adjacent recesses reside along a plurality
of X-planes and a plurality of Y-planes, the slots joining said adjacent recesses
in a direction selected from the group consisting of along a plurality of the X-planes,
along a plurality of the Y-planes, along a plurality of diagonal adjacent X-planes,
along a plurality of diagonal adjacent Y-planes, and any combination thereof.
- 6. The support plate of clause 1 wherein the plurality of slots comprise recessed
slots with each recessed slot connecting two or more of the adjacent recesses to each
other.
- 7. The support plate of clause 6 wherein the recessed slots have at least slot sidewalls
comprising the sheet material.
- 8. The support plate of clause 7 wherein the recessed slots each have a bottom slot
surface and the slot sidewalls comprising the sheet material.
- 9. The support plate of clause 7 wherein the recessed slots each have a slot thickness
extending from the top surface of the plate to the bottom surface of the plate.
- 10. The support plate of clause 1 wherein the plurality of slots comprise open slots
extending through the sheet material at the top surface of the plate and exposing
a top surface of the underlay mat that is attached to the bottom of the plate.
- 11. The support plate of clause 10 wherein the plurality of open slots contact and
join two or more of the adjacent recesses to each other.
- 12. The support plate of clause 10 wherein the plurality of open slots reside between
and do not contact or join any of the adjacent recesses.
- 13. The support plate of clause 10 wherein the plurality of open slots extend partially
into the sidewalls of the recesses from the top surface to the bottom surface of the
plate.
- 14. The support plate of clause 10 wherein the plurality of open slots extending partially
into the recesses leave about 50% sidewall height of the sidewalls within the recesses.
- 15. The support plate of clause 10 wherein the plurality of adjacent recesses comprise
an alternating pattern of circular recesses in combination with flared-square recesses,
wherein adjacent ones of the circular and flared-square recesses are joined together
by the plurality of open slots along one or more directional planes.
- 16. A support plate for installing tile on a substrate comprising:
a sheet material having a top surface and a bottom surface;
a plurality of circular recesses spaced apart and adjacent a plurality of flared-square
recesses, said circular and flared-square recesses residing across the sheet material
and having bottom and sidewalls comprising the sheet material, together the sheet
material and the circular and flared-square recesses define a plate having a thickness
extending from a top surface to a bottom surface thereof;
an underlay mat attached to the bottom surface of the plate; and
a plurality of open slots traversing through the sheet material at the top surface
of the plate and exposing a top surface of the underlay mat, the plurality of open
slots residing between and connecting at least one circular recess to an adjacent
at least one flared-square recess.
- 17. A method of installing facing materials comprising:
providing a substrate;
depositing a first mortar over said substrate;
attaching a support plate to the substrate via the first mortar, the support plate
comprising, a sheet material having a top surface and a bottom surface,
a plurality of adjacent recesses residing across the sheet material, together the
sheet material and the recesses define a plate having a thickness extending from a
top surface to a bottom surface thereof,
an underlay mat attached to the bottom surface of the plate,
a plurality of slots traversing through the sheet material at the top surface of the
plate and residing between the adjacent recesses,
depositing a second mortar over said support plate to fill both said plurality of
recesses and said plurality of slots, said second mortar residing within said plurality
of slots contacting said second mortar residing within said plurality of recesses;
and
providing a facing material over said second mortar.
- 18. The method of clause 17 wherein the plurality of adjacent recesses have one or
more alternating shapes.
- 19. The method of clause 17 wherein the plurality of slots comprise recessed slots.
- 20. The method of clause 17 wherein the plurality of slots comprise open slots extending
through the sheet material at the top surface of the plate and exposing a top surface
of the underlay mat that is attached to the bottom of the plate, said second mortar
filling said plurality of open slots to form mortar pillars residing between the bottom
surface of the sheet material and the top surface of the underlay mat, said mortar
pillars providing additional bonding between said support plate, said second mortar
and said facing material.
[0066] Thus, having described the invention, what is claimed is: